A few days in on my Stage 1 kit...
Have to say its like driving a whole different car.. asides from the chatter that I have to get used to.. a new flywheel really solved a ton of issues and sounds I been hearing and feeling!
My dual mass was pretty much toasted.. the bearing was @ least.. Even the original slave was pretty much seized up! Original clutch with 202K looks just as meaty as the new clutch I got.. lol

but I love it! car feels free!!
I guess I hear chatter out of 1st low in the RPM range, I would say it chatters till about 1800rpms or so...
still haven’t really got on it yet, trying to give it the proper break in!! have about 300miles on it...
Need to power bleed the system to try to get the clutch pedal a little stiffer...

reading about people worrying about the chatter makes me at easy, and to bring you guys further to ease, I put it on 40,000 miles ago....still makes chatter but she still grabs and takes off....no known issues cause from the light weight fly wheel or clutch. Tho every garage I go to tries to tell me its something with the slave or throw out barring.

I really do want to know what the chatter is exactly caused by though.

reading about people worrying about the chatter makes me at easy, and to bring you guys further to ease, I put it on 40,000 miles ago....still makes chatter but she still grabs and takes off....no known issues cause from the light weight fly wheel or clutch. Tho every garage I go to tries to tell me its something with the slave or throw out barring.

I really do want to know what the chatter is exactly caused by though.

Google Self Study Programme 205 or SSP_205.pdf where you'll read about the design of the 02M trans.
Keep in mind this SSP is written with respect to the early production 02M that has tapered bearings.
The basic trans design is the same, only that VW is using roller bearings with plastic cages for late model versions.

You can also Google 02M trans and find videos showing main shaft play, or links to sites discussing the main shaft bearing race issue and someones cheap fix.

Since each gear rides on a needle bearing when not in use, the rotation of the shaft allows the gear to spin freely unless the sliding sleeve/synchromesh body is engaged.

I just checked an 02Q trans on our work bench, each sliding gear makes a different noise when spun, some have a higher pitch sound where others are lower.

The noise is due to the sychro rotating and coming to a rest on the sliding sleeve, the gear will still continue to spin thou.

A dual mass flywheel masks these noises, but a single mass flywheel brings them to light. Every trans is different and between identical models will have different sounds with the clutch depressed or in neutral.

That was very good to read. By your theory, does this chatter (caused by the synchro rotating) cause damage?

Thanks,

Originally Posted by FourSeasonTuning.com

Google Self Study Programme 205 or SSP_205.pdf where you'll read about the design of the 02M trans.
Keep in mind this SSP is written with respect to the early production 02M that has tapered bearings.
The basic trans design is the same, only that VW is using roller bearings with plastic cages for late model versions.

You can also Google 02M trans and find videos showing main shaft play, or links to sites discussing the main shaft bearing race issue and someones cheap fix.

Since each gear rides on a needle bearing when not in use, the rotation of the shaft allows the gear to spin freely unless the sliding sleeve/synchromesh body is engaged.

I just checked an 02Q trans on our work bench, each sliding gear makes a different noise when spun, some have a higher pitch sound where others are lower.

The noise is due to the sychro rotating and coming to a rest on the sliding sleeve, the gear will still continue to spin thou.

A dual mass flywheel masks these noises, but a single mass flywheel brings them to light. Every trans is different and between identical models will have different sounds with the clutch depressed or in neutral.

I haven't seen any damaged as a direct result of the spinning gears, unless the gears touch a neighboring stack.
This causes clutch creep where the vehicle moves forward with the clutch pedal pressed firmly on the floor.

The damage we see are worn main shaft bearings, and its spinning bearing race.
If the spinning race is caught in time, and addressed by any number of cheap fixes, it will save you big time.
If caught late, you are looking at a replacement case, plus shimming every gear stack and diff.

The other issue with the 02M trans is brass shift forks using roll pins.
Weak design, but the replacement steel version are just DSG forks.

This trans is janky by design, so don't expect it to hold up long without routine maintenance.
Become friends with your trans guy or learn to service it yourself (basic tools and mechanical knowledge and a service manual required).

That is very informational. Thank you.
When you mentioned main shaft play, do you refer to the two output shafts in lieu of input shaft?
I have the bentley manual for the car but it has no information regarding the inside of the transmission. Would you like to recommend a manual for the transmission?
Thanks again for your help. I am set to purchase clutch kit from you when I am ready to reassemble and install.

Originally Posted by FourSeasonTuning.com

Chatter/ clatter is a result of a main shaft with excessive play.

I haven't seen any damaged as a direct result of the spinning gears, unless the gears touch a neighboring stack.
This causes clutch creep where the vehicle moves forward with the clutch pedal pressed firmly on the floor.

The damage we see are worn main shaft bearings, and its spinning bearing race.
If the spinning race is caught in time, and addressed by any number of cheap fixes, it will save you big time.
If caught late, you are looking at a replacement case, plus shimming every gear stack and diff.

The other issue with the 02M trans is brass shift forks using roll pins.
Weak design, but the replacement steel version are just DSG forks.

This trans is janky by design, so don't expect it to hold up long without routine maintenance.
Become friends with your trans guy or learn to service it yourself (basic tools and mechanical knowledge and a service manual required).